Interconnectors for a battery assembly

ABSTRACT

A battery module includes multiple electrochemical cells, a circuit board, and multiple interconnectors. Each electrochemical cell includes a terminal. Each of the interconnectors is coupled to the circuit board and to a terminal of one of the electrochemical cells. Each of the interconnectors is a resilient spring-type interconnector.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.12/555,717, filed Jul. 31, 2008, which claims the benefit of andpriority to U.S. Provisional Patent Application No. 61/095,597, filedSep. 9, 2008, and U.S. Provisional Patent Application No. 61/095,569,filed Sep. 9, 2008, and is also a Continuation-in-Part of InternationalApplication No. PCT/IB2008/002011, filed Jul. 31, 2008, which claims thebenefit of and priority to the following German patent applications: DE10 2007 036 595.2, filed Aug. 2, 2007; DE 10 2007 038 252.0, filed Aug.13, 2007; DE 10 2007 051 689.6, filed Oct. 26, 2007; DE 10 2007 058179.5, filed Dec. 1, 2007; DE 10 2007 062 806.6, filed Dec. 21, 2007;and DE 10 2007 062 612.8, filed Dec. 22, 2007. The present applicationclaims the benefit of and priority to, and incorporates herein byreference the entire disclosures of, all of the applications listed inthis paragraph.

BACKGROUND

The present application relates generally to the field of batteries andbattery modules. More specifically, the present application relates tobatteries and battery modules that may be used in vehicle applicationsto provide at least a portion of the motive power for the vehicle.

Vehicles using electric power for all or a portion of their motive power(e.g., electric vehicles (EVs), hybrid electric vehicles (HEVs), plug-inhybrid electric vehicles (PHEVs), and the like, collectively referred toas “electric vehicles”) may provide a number of advantages as comparedto more traditional gas-powered vehicles using internal combustionengines. For example, electric vehicles may produce fewer undesirableemission products and may exhibit greater fuel efficiency as compared tovehicles using internal combustion engines (and, in some cases, suchvehicles may eliminate the use of gasoline entirely, as is the case withcertain types of PHEVs).

As electric vehicle technology continues to evolve, there is a need toprovide improved power sources (e.g., battery modules) for suchvehicles. For example, it is desirable to increase the distance thatsuch vehicles may travel without the need to recharge the batteries. Itis also desirable to improve the performance of such batteries and toreduce the cost associated with the battery modules.

One area of improvement that continues to develop is in the area ofbattery chemistry. Early electric vehicle systems employednickel-metal-hydride (NiMH) batteries as a propulsion source. Over time,different additives and modifications have improved the performance,reliability, and utility of NiMH batteries.

More recently, manufacturers have begun to develop lithium-ion batteriesthat may be used in electric vehicles. There are several advantagesassociated with using lithium-ion batteries for vehicle applications.For example, lithium-ion batteries have a higher charge density andspecific power than NiMH batteries. Stated another way, lithium-ionbatteries may be smaller than NiMH batteries while storing the sameamount of charge, which may allow for weight and space savings in theelectric vehicle (or, alternatively, this feature may allowmanufacturers to provide a greater amount of power for the vehiclewithout increasing the weight of the vehicle or the space taken up bythe battery module).

It is generally known that lithium-ion batteries perform differentlythan NiMH batteries and may present design and engineering challengesthat differ from those presented with NiMH battery technology. Forexample, lithium-ion batteries may be more susceptible to variations inbattery temperature than comparable NiMH batteries, and thus systems maybe used to regulate the temperatures of the lithium-ion batteries duringvehicle operation. The manufacture of lithium-ion batteries alsopresents challenges unique to this battery chemistry, and new methodsand systems are being developed to address such challenges.

Storage battery assemblies are widely used for power supply ofelectronic devices and are of main importance for hybrid vehicles.Hybrid vehicles requires high sophisticated cell arrangements in view ofcooling the storage battery and control of the cells. Therefore, controlunits are provided for a set of cells comprising at least one of atemperature sensor, a voltage sensor, and a current sensor formonitoring the status of a set of cells.

A storage battery assembly for vehicles comprises a high number ofbattery cells which have to be mounted and connected together in ahousing by use of conductive bars. This is time consuming and causeshigh costs of manufacturing. Moreover, the electronic circuitry providedfor monitoring and/or controlling of single battery cells or a group ofbattery cells has to be connected to cell terminals or conductive bars.

Again, establishing the connections is time consuming. Further, due tothe wide temperature range in a battery housing and due to the highvibrational loads to which the storage battery assembly may besubjected, a very stable design of the connections is required.

DE 10 2005 055 418 B3 discloses, for example, a storage battery assemblycomprising a plurality of prismatic battery cells connected to eachother by use of terminals extending to a battery cell housing andcarrying an U-formed connection plate. An adjacent battery cell isplugged into the U-formed connection plate and is welded with itshousing providing the negative pole to the connection plate.

DE 100 11 233 B4 discloses a battery pack comprising temperature sensorslocated on a row of battery cells for measuring the temperature of thebattery cells.

DE 10 2004 043 138 A1 discloses a battery cover comprising integratedcontact portions for connecting to the battery terminals and comprisingelectronic circuitry. The battery cover can be placed on top of abattery comprising a plurality of battery cells and is intended for usewith a starter battery.

EP 1 250 720 B1 discloses a battery cell comprising a battery cellhousing and electronic circuitry incorporated into the battery cellhousing. A battery cell terminal is connected to the electroniccircuitry by use of a spring contact member. The electrodes inside thebattery cell housing are connected to a contact plate at the bottom sideof the circuit board comprising the electronic circuitry.

US 2006/0091891 A1 discloses a battery assembly comprising a pluralityof prismatic battery cells and bus bars on the top of the cell assemblyfor connecting adjacent battery cell terminals. Temperature measurementmembers are attached to the bus bars. A printed circuit board made of athin cupper laminate is connected to the bus bar. A circuit is printedat the printed circuit board to which electric current is transmittedfrom the bus bar via protrusions and an electric current is transmittedfrom a thermistor via through holes. The printed circuit board isconnected to a battery management system, at which a voltage measuringdevice and a temperature measuring device are mounted.

KR 10 2004 0005066 A discloses a device for connecting battery cells ofhybrid electric vehicles comprising a printed circuit board equippedwith an electrical circuit for serial or parallel connection of thecells of a battery. The printed circuit board is electrically connectedto each of the cells to connect cells in a serial or parallel manner. Avoltage measurement connection socket is connected to the electricalcircuit of the printed circuit board and a cell voltage measurementunit.

GB 2 375 223 A discloses a battery management system comprising aprinted circuit board and a plurality of electrochemical cells. Theprinted circuit board is plugged onto cell terminals protruding from thebattery cell housing and screwed onto the battery terminals by nuts. Theprinted circuit board carries hardware and software components in anumber of sensors for monitoring and controlling the battery pack.Further, the printed circuit board carries tracks for connecting a pairof cell terminals respectively. Thus, a connection of battery cellsserial or parallel and a connection of battery terminals to electroniccircuitry for monitoring and controlling battery cells is achieved inone step simply by screwing the printed circuit board onto the cellterminals.

DE 10 2006 002 457 A1 discloses an electrical connector between aprinted circuit board and a battery terminal. An electric conductivebushing mounted in a hole of the printed circuit board is plugged andwelded onto a battery terminal post.

U.S. Pat. No. 7,028,389 B2 discloses a fixing device for a printedcircuit board comprising an elastic washer mounted between the printedcircuit board and a fixing pillar. Electric current is able to flow fromconductive lines on the printed circuit board through the elastic washerand the fixing pillar to a shell.

DE 203 20 473 U1 discloses a shunt provided in a plate like connectorelement for cell terminals.

It would be desirable to provide an improved battery module and/orsystem for use in electric vehicles that addresses one or morechallenges associated with NiMH and/or lithium-ion battery modules usedin such vehicles. It would also be desirable to provide a battery moduleand/or system that includes any one or more of the advantageous featuresthat will be apparent from a review of the present disclosure.

SUMMARY

According to an exemplary embodiment, a battery module includes multipleelectrochemical cells, a circuit board, and multiple interconnectors.Each electrochemical cell includes a terminal. Each of theinterconnectors is coupled to the circuit board and to a terminal of oneof the electrochemical cells. Each of the interconnectors is a resilientspring-type interconnector.

According to an exemplary embodiment, a battery module includes multipleelectrochemical cells, a circuit board, and multiple interconnectors.Each electrochemical cell includes a terminal. Each of theinterconnectors is coupled to the circuit board and to a terminal of oneelectrochemical cells. Each of the interconnectors is a resilientspring-type interconnector. The circuit board is configured to allow theinterconnectors to be substantially simultaneously conductively coupledto the terminals of the electrochemical cells.

According to an exemplary embodiment, a batter module includes multipleelectrochemical cells where each of the electrochemical cells includes aterminal projecting from an end thereof and a member having multipleinterconnectors coupled thereto. Each of the interconnectors is coupledto a terminal of one of the electrochemical cells to aid in measuringthe voltage of the electrochemical cell.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a vehicle including a battery moduleaccording to an exemplary embodiment.

FIG. 2 is a cut-away schematic view of a vehicle including a batterymodule according to an exemplary embodiment.

FIG. 3 is a perspective view of a storage battery assembly for vehiclesaccording to an exemplary embodiment.

FIG. 4 is a cross-sectional view of a battery assembly comprising afirst embodiment of an interconnection washer.

FIG. 5 is a cross-sectional view of a second embodiment of aninterconnection washer clipped onto a printed circuit board.

FIG. 6 is a top view of the interconnection washer of FIG. 5.

FIG. 7 is a top view of a battery assembly comprising a printed circuitboard mounted onto a plurality of battery cells according to anexemplary embodiment.

FIG. 8 is a top view of the battery assembly of FIG. 7 includingconductive bars according to an exemplary embodiment.

FIG. 9 is a top view of a battery assembly comprising two sections ofbattery assemblies according to FIG. 8 connected to each other accordingto an exemplary embodiment.

FIG. 10 is a top view of a battery assembly comprising two sections ofbattery assemblies and a rectangular printed circuit board according toan exemplary embodiment.

FIG. 11 is a top view of another battery assembly according to anexemplary embodiment.

FIG. 12 is a top view of still another arrangement of a battery assemblyaccording to an exemplary embodiment.

FIG. 13 is a perspective view of a third embodiment of aninterconnection washer.

FIG. 14 is a perspective view of a battery cell connected to a printedcircuit board with the interconnection washer according to FIG. 13according to an exemplary embodiment.

FIG. 15 is a perspective view of a battery module having a washerassembly according to another exemplary embodiment.

FIG. 16 is a bottom perspective view of the washer assembly of FIG. 15.

FIG. 17 is a partial exploded view of the battery module of FIG. 15.

FIG. 18 is a partial cross-sectional view of the battery module of FIG.17 taken along lines 18-18 of FIG. 17.

FIG. 19 is a detail view of a portion of the washer assembly of FIG. 18according to an exemplary embodiment.

FIG. 20 is a partial perspective cut-away view of the washer assembly ofFIG. 15.

FIG. 21 is a bottom partial perspective cut-away view of the washerassembly of FIG. 20.

FIG. 22 is a partial perspective cut-away view of the washer assembly ofFIG. 21.

FIG. 23 is a partial perspective view of the washer assembly of FIG. 16according to an exemplary embodiment.

FIG. 24 is a partial exploded view of the washer assembly of FIG. 23according to an exemplary embodiment.

DETAILED DESCRIPTION

According to an exemplary embodiment, a storage battery assembly forvehicles includes a plurality of electrochemical cells (e.g., batteries,cells, etc.). Each cell comprises a closed housing and at least oneterminal extending from the cell housing. Electrical conductive bars aremounted on dedicated terminals. The conductive bars electrically connectthe cells. At least one circuit board includes electronic circuitry formonitoring and/or controlling the cells.

FIG. 1 is a perspective view of a vehicle 110 in the form of anautomobile (e.g., a car) having a battery module 120 for providing allor a portion of the motive power for the vehicle 110. Such a vehicle 110can be an electric vehicle (EV), a hybrid electric vehicle (HEV), aplug-in hybrid electric vehicle (PHEV), or other type of vehicle usingelectric power for propulsion (collectively referred to as “electricvehicles”).

Although the vehicle 110 is illustrated as a car in FIG. 1, the type ofvehicle may differ according to other exemplary embodiments, all ofwhich are intended to fall within the scope of the present disclosure.For example, the vehicle 110 may be a truck, bus, industrial vehicle,motorcycle, recreational vehicle, boat, or any other type of vehiclethat may benefit from the use of electric power for all or a portion ofits propulsion power.

Although the battery module 120 is illustrated in FIG. 1 as beingpositioned in the trunk or rear of the vehicle, according to otherexemplary embodiments, the location of the battery module 120 maydiffer. For example, the position of the battery module 120 may beselected based on the available space within a vehicle, the desiredweight balance of the vehicle, the location of other components usedwith the battery module 120 (e.g., battery management systems, vents orcooling devices, etc.), and a variety of other considerations.

FIG. 2 illustrates a cut-away schematic view of a vehicle 110 providedin the form of an HEV according to an exemplary embodiment. A batterymodule 120 is provided toward the rear of the vehicle 110 proximate afuel tank 112 (the battery module 120 may be provided immediatelyadjacent the fuel tank 112 or may be provided in a separate compartmentin the rear of the vehicle 110 (e.g., a trunk) or may be providedelsewhere in the vehicle 110). An internal combustion engine 114 isprovided for times when the vehicle 110 utilizes gasoline power topropel the vehicle 110. An electric motor 116, a power split device 117,and a generator 118 are also provided as part of the vehicle drivesystem.

Such a vehicle 110 may be powered or driven by just the battery module120, by just the engine 114, or by both the battery module 120 and theengine 114. It should be noted that other types of vehicles andconfigurations for the vehicle drive system may be used according toother exemplary embodiments, and that the schematic illustration of FIG.2 should not be considered to limit the scope of the subject matterdescribed in the present application.

According to various exemplary embodiments, the size, shape, andlocation of the battery module 120, the type of vehicle 110, the type ofvehicle technology (e.g., EV, HEV, PHEV, etc.), and the batterychemistry, among other features, may differ from those shown ordescribed.

Referring to FIG. 3, a battery module or assembly 1 is shown accordingto an exemplary embodiment. According to an exemplary embodiment, thebattery assembly 1 is responsible for packaging or containingelectrochemical batteries or cells 2, connecting the electrochemicalcells 2 to each other and/or to other components of the vehicleelectrical system, and regulating the electrochemical cells 2 and otherfeatures of the battery assembly 1. For example, the battery assembly 1may include features that are responsible for monitoring and controllingthe electrical performance of the battery assembly 1, managing thethermal behavior of the battery assembly 1, containment and/or routingof effluent (e.g., gases that may be vented from a cell 2), and otheraspects of the battery assembly 1.

According to an exemplary embodiment, the battery assembly 1 includes aplurality of electrochemical cells 2 (e.g., lithium-ion cells,nickel-metal-hydride cells, lithium polymer cells, etc., or other typesof electrochemical cells now known or hereafter developed). According toan exemplary embodiment, the electrochemical cells 2 are generallycylindrical lithium-ion cells configured to store an electrical charge.According to other exemplary embodiments, the electrochemical cells 2could have other terminal configurations or physical configurations(e.g., oval, prismatic, polygonal, etc.). The capacity, size, design,and other features of the electrochemical cells 2 may also differ fromthose shown according to other exemplary embodiments.

Each of the electrochemical cells 2 are electrically coupled to one ormore other electrochemical cells 2 or other components of the batteryassembly 1 using connectors provided in the form of bus bars 5 orsimilar elements. According to an exemplary embodiment, the bus bars 5are housed or contained in bus bar holders (not shown). According to anexemplary embodiment, the bus bars 5 are constructed from a conductivematerial such as copper (or copper alloy), aluminum (or aluminum alloy),or other suitable material. According to an exemplary embodiment, thebus bars 5 may be coupled to terminals 4 a, 4 b of the electrochemicalcells 2 by welding (e.g., resistance welding) or through the use offasteners (e.g., a bolt or screw may be received in a hole at an end ofthe bus bar 5 and screwed into a threaded hole in the terminal).

Although illustrated in FIG. 2 as having a particular number ofelectrochemical cells 2 (i.e., three rows of electrochemical cellsarranged such that three electrochemical cells are arranged in each row,for a total of nine electrochemical cells), it should be noted thataccording to other exemplary embodiments, a different number and/orarrangement of electrochemical cells 2 may be used in the batteryassembly 1 depending on any of a variety of considerations (e.g., thedesired power for the battery assembly 1, the available space withinwhich the battery assembly 1 must fit, etc.).

According to an exemplary embodiment, the plurality of electrochemicalcells 2 are provided in a first member, structure, housing, or tray (notshown). According to an exemplary embodiment, the tray receives theindividual electrochemical cells 2 in the proper orientation forassembling the battery assembly 1. According to an exemplary embodiment,the tray may also include features to provide spacing of theelectrochemical cells 2 away from the bottom of the tray and/or fromadjacent cells. For example, according to an exemplary embodiment, thetrays may include a series of features (e.g., openings, apertures,sockets, etc.) to locate and hold the electrochemical cells 2 inposition above a bottom of the tray. According to an exemplaryembodiment, the tray may be made of a polymeric material or othersuitable material (e.g., electrically insulated material). A cover (notshown) and/or a base plate (not shown) may be provided to partially orcompletely surround or enclose the cells 2 and the trays.

Still referring to FIG. 3, according to an exemplary embodiment, theelectrochemical cells 2 are generally cylindrical lithium-ion cells 2configured to store an electrical charge. The cells 2 include acylindrical housing 3 having a positive terminal 4 a and a negativeterminal 4 b on one end and a vent (not shown) on an opposite end.According to other exemplary embodiments, the cells 2 could have otherterminal configurations or physical configurations (e.g., oval,prismatic, polygonal, etc.). The capacity, size, design, terminalconfiguration, and other features of the cells 2 may also differ fromthose shown according to other exemplary embodiments.

One advantageous feature of the embodiments described herein is that animproved storage battery assembly may be provided which may be assembledin a manner that provides cheap interconnection of a circuit board andcell terminals and easy and reliable interconnection of cell terminalsto each other by use of conductive bars.

This advantage is achieved with a storage battery assembly for vehiclescomprising a plurality of battery cells, each battery cell comprising aclosed cell housing and at least one cell terminal extending from thecell housing, electrical conductive bars mounted on dedicated cellterminals, the conductive bars electrically connecting battery cells andat least one circuit board comprising an electric circuitry provided formonitoring and/or controlling of battery cells, wherein cell terminalsare carrying electrically conductive interconnection washers mountedthereon, wherein the interconnection washers extending to a dedicatedcircuit board and being connected with electronic circuitry on therespective circuit board, and wherein the circuit board is connected toat least one interconnection washer being located adjacent to the atleast one cell terminal to which the at least one interconnection washeris connected.

According to an exemplary embodiment, electric conductive bars aremounted on dedicated cell terminals independent from the at least onecircuit board. The at least one circuit board is connected to dedicatedcell terminals by use of interconnection washers. The interconnectionwasher has the advantage, that the connection of a cell terminal and acircuit board can be made close to the cell terminal. Further, thewasher can be mounted onto the cell terminal together with the bus bar.

The at least one interconnection washer is preferably elastic (e.g.,flexible), so that the washer and the connection between the circuitboard and the battery terminal by use of the washer withstands highvibrational load.

Further it is preferred that at least one of the circuit boards islocated between the respective battery cell housing and conductive bars.In this preferred embodiment, the intermediate space between the batterycell housing and the conductive bars are used to place the circuitboards. The advantage of this design is that the circuit board can befastened in the gap between the cell housing and the conductive bars bythe conductive bars themselves. The contact between the battery cellterminals and the circuit boards is established by use of theinterconnection washers, which are also securely fastened by theconductive bars mounted to the battery terminals.

In order to avoid short circuits especially when using electricconductive cell housings, an insulation layer should be provided betweenthe circuit board and the adjacent cell housing and/or an adjacentconductive bar. The insulation layer can be made as integral part of theprinted circuit board. In a preferred embodiment, at least one of thecircuit boards comprises holes corresponding to the location of the cellterminals. The circuit boards are located on battery cells with the cellterminals extending through respective holes of the circuit board. Thus,when mounting a storage battery assembly, first the circuit boards areprovided over the cell terminals with the interconnection washersextending from the printed circuit board to the respective battery cellterminals. Second, the conductive bars are fastened to respectivebattery cell terminals, whereby electrically connecting adjacent batterycells and dedicated washers and establishing an electrical conductiveconnection of battery cell terminals and interconnection washers.

Advantageously, at least one of the circuit boards is placed on top ofat least one of the cell housings with the cell terminals extendingthrough the at least one circuit board. The interconnection washers aremounted to the extending cell terminals having flexible or elastic legsof a height being greater than the gap between the upper surface of acircuit board to which the interconnection washer is connected and theconnection between the interconnection washer and the respective cellterminal. The flexible or elastic legs are spring biased to the circuitboard when connecting the respective interconnection washer to thededicated cell terminal.

By use of the flexible or elastic legs of the interconnection washershaving a height being greater than the gap between the upper surface ofthe circuit board in the connection, a spring biased contact of thewasher to the printed circuit board is achieved, which can withstandhigh vibrational load. Further, it is of advantage when at least one ofthe circuit boards is flexible.

The at least one interconnection washer can be welded or soldered to aconductive path on a dedicated circuit board. Soldering or welding theinterconnecting washer to the dedicated conductive path on the circuitboard has the advantage over a press contact to be more reliable.Further, the interconnection washer can be welded or soldered to theprinted circuit board before mounting the printed circuit board onto thebattery cell assembly. Thus, the printed circuit board can be assembledin one step to the terminals of the battery cells. In a next step, theconductive bars are installed on the battery cell terminals, therebyfastening the washers to the cell terminals.

In another preferred embodiment, the interconnection washers are placedon top of a free end of a dedicated cell terminal. The conductive barsare placed on top of a respective interconnection washer. The cellterminals comprise internal threads and the interconnection washers andconductive bars comprise respective openings. A cell terminal, aninterconnection washer, and a conductive bar are mounted together by afastener (e.g., a screw) extending through the openings of theconductive bar and the interconnection washer and screwed into theinternal thread of the cell terminal. The use of the internal thread inthe cell terminal has the advantage that the cell terminal,interconnection washer, and conductive bar can be mounted together inone step providing a highly reliable electrical and mechanicalconnection, which can also withstand high vibrational loads.

In another preferred embodiment, the at least one interconnection washeris formed by a metal cap comprising a base plate, a side wallcircumferentially surrounding the base plate, and a foot plate extendingfrom the side wall to the outside at the lower edge of the opposite sideof the base plate forming a rest or stop for a circuit board. The baseplate is located at an upper edge of the side wall. Spring legs extendfrom the side wall in the direction to the rest and away from the cap.The spring legs provided on the cap have a length adapted to spring biasa circuit board resting on the rest. Thus, the printed circuit board canbe provided onto the interconnection washer and can be held by the footplate forming a rest for the circuit board and by the spring legsforming a stud.

In another preferred embodiment, at least one of the interconnectionwashers is formed by an upper metal ring and a lower metal ring and ametal plate extending from the lower metal ring to the upper metal ring.The metal plate is integrally formed with the upper metal ring and thelower metal ring providing a spring element between the lower metal ringand the upper metal ring. The lower metal ring is mounted on a cellterminal and the upper metal ring is mounted on a circuit board.Preferably, the lower metal ring has a diameter smaller than a diameterof the upper metal ring. Then, the metal plate is helically wound with adiameter increasing from the connection point with a lower metal ring tothe connection point with the upper metal ring. Preferably, the metalplate extends from the inner edge of the upper metal ring to the outeredge of the lower metal ring.

The interconnection washer can be picked and placed and soldered onto aprinted circuit board as any other electronic component. Due to themetal plate extending from the lower metal ring to the upper metal ring,the interconnection washer has an elastic compliance (i.e., it isflexible) in the z-axis parallel to the axis of the cell terminal thatcan accommodate high vibrational loads and unplanarity of the cellterminals and which does not stress the solder joint. The design ensureslong term electrical connection between the printed circuit board andthe cell electrode terminals.

In a preferred embodiment, a temperature sensor is installed on themetal connection path between the cell terminal and the electroniccircuitry. Preferably, the temperature sensor is mounted on theinterconnection washer. The temperature sensor is electrically connectedto the electronic circuitry provided for monitoring the state of the atleast one battery cell connected to the respective metal connectionpath.

Because of the good thermal conductivity of the copper parts or contactsin between the temperature sensor and the cell terminal, the temperaturewhich is measured is highly reproducible and less sensitive todisturbances or perturbation induced by, e.g., a battery cooling system,than previous temperature sensing methods.

The temperature sensor can be very small and surface mountable and thuscan be picked and placed and soldered on the printed circuit board asother electronic components. Assembly cost is reduced to a minimum.Further, there is no need for wires or a connector between thetemperature sensor and the measuring circuitry. Material cost is alsoreduced to a minimum.

The temperature sensors are able to approximate the temperature ofelectrodes of the cells due to a well defined correlation between theinternal temperature of the cell electrodes and the metal partscomprising the cell electrodes and terminals.

Current measurement for a series of the battery cells is preferablyperformed by use of a shunt. In a preferred storage battery assembly, atleast one of the conductive bars provided for connecting cell terminalswith each other or with a power line has an integrated shunt.

FIG. 3 shows a storage battery assembly 1 comprising a plurality ofbattery cells 2 placed side-by-side of each other. The battery cells 2each comprise a cylindrical-shaped housing 3 incorporating woundelectrodes and electrolyte as it is known per se.

Cell terminals 4 a, 4 b are protruding out of the respective cellhousing 3. A first battery terminal is provided for the positive poleand a second cell terminal 4 b is provided for the negative pole of thebattery cell 2.

The battery cells 2 are connected in series by use of conductive bars 5.The conductive bars 5 each connect a positive cell terminal 4 a of afirst battery cell 2 and a negative battery terminal 4 b of an adjacentbattery cell 2.

In order to monitor the state of each of the battery cells 2, a controlunit 6 is provided for each of the battery cells 2 and located close bythe battery terminals 4 a, 4 b of a respective battery cell. The controlunit 6 comprises a printed circuit board and electronic circuitryprovided to monitor and/or control the state and the load-unload cycleof the dedicated battery cell 2. The electronic circuitry can optionallyinclude sensors, like temperature sensors, voltage sensors and/orcurrent sensors, or can be connected to such sensors located separatelyfrom the printed circuit board.

The connection of the control unit 6 and the cell terminals 4 a, 4 b ofa respective battery cell 2 is established by means of interconnectionwashers 7 extending from the battery terminals 4 a, 4 b to theadjacently-located printed circuit board of the control unit 6. Theinterconnection washers 7 are mounted on the respective cell terminal 4a, 4 b together with the dedicated conductive bar 5.

FIG. 4 shows a cross-section view of a battery cell assembly. Thebattery cell 2 and the cell terminal 4 extending over the batteryhousing 3 is clearly visible in the side view. The cell terminal 4comprises an internal thread 8 being aligned parallel to thelongitudinal direction of the cell terminal 4, preferably in the centerof the cell terminal 4.

A printed circuit board 9 carrying electronic circuitry for establishingthe control unit 6 is installed on top of the cell housing 3. Theprinted circuit board 9 comprises an opening in alignment with the cellterminal positions so that at least one cell terminal 4 extends throughthe opening 10 of the printed circuit board 9. The printed circuit board9 carries conductive lines 11 (e.g., made from copper or copper alloy),which are connected to electronic circuitry (not shown). Aninterconnection washer 7 is coupled (e.g., soldered or welded) to adedicated conductive line 11 on the printed circuit board 9. Theembodiment of the interconnection washer 7 shown in FIG. 4 is formedlike a tongue and placed on top of the free end of the cell terminal 4.The interconnection washer 7 is angled downward from the top of therespective battery cell 2 in direction to the conductive line 11 of theprinted circuit board 9 so as to weld or solder the free end of theinterconnection washer 7 to the conductive line 11.

The conductive bar 5 is placed on top of the interconnection washer 7and the cell terminal 4. Both the conductive bar 5 and theinterconnection washer 7 comprise openings 12 in alignment with eachother and the internal thread 8 of the cell terminal 4 so as to allow afastening screw extending through the openings 12 into the internalthread 8 and to fasten the conductive bar 5, interconnection washer 7,and cell terminal 4 together.

FIG. 5 shows a second embodiment of an interconnection washer 7. Theinterconnection washer 7 has the form of a cap comprising a metal baseplate 13. The base plate 13 has the form of a ring comprising theopening 12 for inserting a fastening screw (not shown). A side wall 14is integrally formed with the base plate 13. The side wall 14circumferentially surrounds the base plate 13. The base plate 13 islocated at the upper edge of the side wall 14. Integrally formed withthe lower edge of the side wall 14 is a foot plate 15 having a ring formsimilar to the base plate 13, but with an increased diameter. The footplate 15 extends from the side wall 14 to the outside in contrast to thebase plate 13 extending from the side wall 14 to the inside of thecap-formed interconnection washer 7. The foot plate 15 forms a rest orstop for a circuit board 9 which is clipped onto the interconnectionwasher 7 from the side of the base plate 13 into the direction of thefoot plate 15.

Spring legs 16 are extending from the side wall 14 in the direction ofthe printed circuit board 9 and the rest or stop provided by the footplate 15 and extending away from the cap-formed interconnection washer7. The length of the spring legs 16, which are folded in the directionof the side wall 14 at their free ends, are adapted to the thickness ofthe printed circuit board 9 intended to be installed onto theinterconnection washer 7 so as to spring bias the circuit board 9 ontothe interconnection washer 7.

The printed circuit board 9 in combination with this embodiment of theinterconnection washer 7 is preferably rigid, whereas the printedcircuit board 9 of the first embodiment shown in FIG. 4 can be rigid orpreferably flexible. The interconnection washer 7 shown in any of theembodiments may be rigid, semi-rigid, flexible, or semi-flexible.

FIG. 6 shows a top view of the interconnection washer 7 of FIG. 5. Itshould be noted that the interconnection washer 7 is mounted on top ofthe cell terminal 4 so that the inner surface of the base plate 13 restson the free end of the battery cell terminal 4.

FIG. 7 shows a top view of a storage battery assembly comprising aserrated printed circuit board 9 installed on top of a plurality ofbattery cells 2. The form of the printed circuit board 9 is adapted tothe staggered arrangement of the battery cells 2. The interconnectionwashers 7 clipped onto the printed circle board 9 are protruding overthe upper surface of the printed circuit board 9 and located on top ofthe free end of the battery cell terminals 4 a, 4 b.

FIG. 8 shows the storage battery assembly 1 of FIG. 7 with theconductive bars 5 mounted on top of the interconnection washers 7 andthe dedicated cell terminals 4 a, 4 b. The battery cells 2 groupedside-by-side to each other in a staggered layout are electricallyconnected in series to each other by use of the conductive bars 5. Thestaggered arrangement of the battery cells 2 enhances the packagedensity.

FIG. 9 shows a storage battery assembly 1 comprising two sections ofbattery assemblies 1 a, 1 b, as shown in FIG. 8. The serrated design ofthe printed circuit board 9 has the advantage that two sections ofbattery assemblies 1 a, 1 b including the serrated printed circuitboards 9 can be arranged into one another (e.g., nested with oneanother). The sections of storage battery cell arrangements 1 a, 1 b areelectrically connected to each other by use of an interconnectionconductive bar 17 similar to the conductive bars 5 of each section 1 a,1 b.

FIG. 10 shows a top view of a similar design according to FIG. 9. Theonly difference is the design of the printed circuit boards 9, which arerectangular. The battery cells 2 are connected to each other with theconductive bars 5 (e.g., in a generally zig-zag pattern).

FIG. 11 shows a top view of another embodiment of a storage batteryassembly 1. The staggered battery cells 2 are connected to each otherwith conductive bars 5 of two different lengths.

FIG. 12 shows another embodiment of the storage battery assembly 1comprising conductive bars 5 of two different lengths, wherein thelonger conductive bars 5 are provided for connecting the outer cellterminals in a first longitudinal direction. The shorter conductive bars5 are provided for connecting battery terminals 4 a, 4 b of the adjacentbattery cells 2 extending diagonal to the longer conductive bars 5.

FIG. 13 shows a third embodiment of an interconnection washer 7comprising an upper metal ring 18 and a lower metal ring 19 each havingan opening and being in line to each other. The upper and lower metalring 18, 19 are placed at a distance from each other, the distance beingbridged by a metal plate 20 extending from the upper metal ring 18 tothe lower metal ring 19. It should be noted that the interconnectionwasher 7 is turned upside-down in FIG. 13 compared to its installationposition in order to be able to show the details of the washer.

As can be seen from FIG. 13, the metal plate 20 extends from the inneredge of the upper metal ring 18 to the outer end edge of the lower metalring 19 and is helically curved with the diameter increasing from theconnection point with the lower metal ring 19 to the connection pointwith the upper metal ring 18. The lower metal ring 19 has a smallerdiameter than the upper metal ring 18.

The interconnection washer 7 of FIG. 13 can be picked and placed andsoldered onto a printed circuit board 9 as it is shown in theperspective view of FIG. 14. Thus, the interconnection washer 7 can behandled as any other electronic component 21 mounted onto the printedcircuit board 9. It should be noted that the arrangement shown in FIG.14 is presented upside down to its typical position.

The interconnection washer 7 is flexible (i.e., has an elasticcompliance) in the z-axis that can withstand high vibrational loads andaccommodate the unplanarity of the cell terminals 4 a, 4 b as to notstress the solder joint of the interconnection washer 7 and the lines 11of the printed circuit board 9. Therefore, the interconnection washer 7may provide long term electrical connection between the printed circuitboard 9 and the cell terminal 4 a, 4 b.

As can be seen in FIG. 14, the conductive bars 5 each provided forelectrical connecting adjacent battery cells 2 are located between thefree end of a cell terminal 4 a, 4 b and the upper surface of thesmaller lower metal ring 19.

According to an exemplary embodiment, temperature sensors 22 areinstalled directly on the printed circuit board 9 that performs thetemperature measurement. One terminal of the temperature sensor 22 iselectrically (and thus thermally) connected to a copper track of theprinted circuit board 9 which is electrically (and thus thermally)connected to a cell electrode terminal 4 a, 4 b, by means of aconnecting device such as an interconnection washer 7 (e.g., in form ofa spring contact). The voltage at the cell terminal 4 b which thetemperature sensor 22 is connected to, is the ground reference voltagefor the electronic circuitry 21 that performs the temperaturemeasurement. The other terminal of the temperature sensor 22 isconnected to the input of the electronic circuitry 21 that performs thetemperature measurement.

The advantages of this solution are because of the good thermalconductivity of the copper parts or contacts in between the temperaturesensor 22 and the cell terminal 4 b, the temperature which is measuredis much more representative of the cell internal temperature than withprevious temperature sensing solutions. Moreover, the measurement ismuch more reproducible and less sensitive to disturbance induced by, forexample, a battery cooling system, than previous temperature sensingmethods.

The temperature sensors 22 can be very small and surface mountable(e.g., a surface mountable device) and thus can be picked and placed andsoldered on the printed circuit board 9 as other electronic components.Assembly costs are reduced to a minimum. There is no need for wires norconnectors between the temperature sensor 22 and the measuring circuitry21. Material costs are also reduced to a minimum.

The installation of the temperature sensor 22 makes use of the fact thatthere is a well defined correlation between the internal temperature ofthe battery cell 2 and the metal parts composing the cell electrode andterminals 4 a, 4 b. Measuring the temperature of such cell terminals 4a, 4 b is much more accurate than measuring the ambient air betweenadjacent cells.

For measuring the current that flows in or out the battery assembly, ashunt 23 is provided on at least one conductive bar 5. A shunt 23 offersa good accuracy over a wide range of current measurement. According toan exemplary embodiment, the shunt 23 is integrated into one of thecopper bars 5 connecting two consecutive cells 2 of the battery assembly1.

The resulting conductive bar 5 is a composite device composed of threeparts, a first copper part, connected to one cell electrode terminal 4 bof a given polarity, a second resistive alloy part, i.e., the shunt 23,across which will be measured the voltage drop proportional to thecurrent flowing through it, and a third copper part, connected to theelectrode terminal 4 a of opposite polarity of the consecutive batterycell 2 in the battery assembly 1.

A preferred embodiment consists of connecting the shunt bar between thebattery assembly negative pole and the first battery cell 2 of thebattery assembly 1, or between the first and the second battery cells 2of the battery assembly 1.

There are many cost advantages for this solution. First, there is noneed for additional power wiring between the shunt 23 and the batteryterminals 4 a, 4 b, nor additional fasteners (e.g., bolts and nuts) toconnect the cables to the shunt 23. Second, there is no additionalcomponent needed. Instead, the shunt 23 is included in one of theconductive connection bars 5 between two consecutive battery cells 2.Further, the connections between each side of the resistive alloy of theshunt 23 and the printed circuit board 9 on which is assembled theelectronic circuitry 21 (which is able to measure the voltage dropacross the shunt 23) are optimized in terms of length. In addition, thespace and weight required to perform the current measurement arereduced, which is a significant advantage considering the space andweight requirements of a battery system.

Referring now to FIGS. 15-24, a battery module 120 is shown according toan exemplary embodiment. According to an exemplary embodiment, thebattery module 120 includes electrochemical batteries or cells 130, andincludes features or components for connecting the electrochemical cells130 to each other and/or to other components of the vehicle electricalsystem, and also for regulating the electrochemical cells 130 and otherfeatures of the battery module 120. For example, the battery module 120may include features that are responsible for monitoring and controllingthe electrical performance of the battery module 120, managing thethermal behavior of the battery module 120, containment and/or routingof effluent (e.g., gases that may be vented from a cell 130), and otheraspects of the battery module 120.

According to an exemplary embodiment, the battery module 120 includes aplurality of electrochemical cells 130 (e.g., lithium-ion cells,nickel-metal-hydride cells, lithium polymer cells, etc., or other typesof electrochemical cells now known or hereafter developed). According toan exemplary embodiment, the electrochemical cells 130 are generallycylindrical lithium-ion cells configured to store an electrical charge.According to other exemplary embodiments, the electrochemical cells 130could have other physical configurations (e.g., oval, prismatic,polygonal, etc.). The capacity, size, design, and other features of theelectrochemical cells 130 may also differ from those shown according toother exemplary embodiments.

Each of the electrochemical cells 130 are electrically coupled to one ormore other electrochemical cells 130 or other components of the batterymodule 120 using connectors provided in the form of bus bars 152 orsimilar elements (see, e.g., FIG. 17). According to an exemplaryembodiment, the bus bars 152 are housed or contained in a bus bar holder150. According to an exemplary embodiment, the bus bars 152 areconstructed from a conductive material such as copper (or copper alloy),aluminum (or aluminum alloy), or other suitable material. According toan exemplary embodiment, the bus bars 152 may be coupled to terminals136, 138 of the electrochemical cells 130 by welding (e.g., resistancewelding) or through the use of fasteners (e.g., a bolt or screw 142 maybe received in a hole 153 at an end of the bus bar 152 and screwed intoa threaded hole in the terminal 136, 138).

Although illustrated in FIG. 15 as having a particular number ofelectrochemical cells 130 (i.e., five rows of electrochemical cellsarranged such that seven electrochemical cells are arranged in each row,for a total of 35 electrochemical cells), it should be noted thataccording to other exemplary embodiments, a different number and/orarrangement of electrochemical cells 130 may be used in the batterymodule 120 depending on any of a variety of considerations (e.g., thedesired power for the battery module 120, the available space withinwhich the battery module 120 must fit, etc.).

According to an exemplary embodiment, the plurality of electrochemicalcells 130 are provided in a first member, structure, housing, or tray(not shown). According to an exemplary embodiment, the tray receives theindividual electrochemical cells 130 in the proper orientation forassembling the battery module 120. According to an exemplary embodiment,the tray may also include features to provide spacing of theelectrochemical cells 130 away from the bottom of the tray and/or fromadjacent cells. For example, according to an exemplary embodiment, thetrays may include a series of features (e.g., openings, apertures,sockets, etc.) to locate and hold the electrochemical cells 130 inposition above a bottom of the tray. According to an exemplaryembodiment, the tray may be made of a polymeric material or othersuitable material (e.g., electrically insulated material). A cover 122and/or a base plate (not shown) may be provided to partially orcompletely surround or enclose the cells 130 and the trays.

Referring to FIG. 17, according to an exemplary embodiment, theelectrochemical cells 130 are generally cylindrical lithium-ion cells130 configured to store an electrical charge. The cells 130 include acylindrical housing 132 having a positive terminal 136 and a negativeterminal 138 on one end and a vent (not shown) on an opposite end.According to other exemplary embodiments, cells 130 could have otherterminal configurations or physical configurations (e.g., oval,prismatic, polygonal, etc.). The capacity, size, design, terminalconfiguration, and other features of the cells 130 may also differ fromthose shown according to other exemplary embodiments.

Referring to FIG. 15, the battery module 120 includes a bus bar assembly150 and a washer assembly 160. According to an exemplary embodiment, thebus bar assembly 150 comprises a plurality of bus bars 152 providedbetween an upper member 154 and a lower member 156 (e.g., as shown inFIG. 17). According to another exemplary embodiment, only one member(e.g., either the upper member 154 or lower member 156) may be providedwith the plurality of bus bars 152. According to an exemplaryembodiment, the bus bars 152 are coupled to at least one of the upper orlower members 154, 156 (e.g., by an adhesive). According to an exemplaryembodiment, the upper member 154 and/or lower member 156 may be madefrom a flexible material (such as Mylar®), a rigid material, or anyother suitable material.

As shown in FIG. 17, each of the plurality of bus bars 152 includes anaperture 153 at either end of the bus bar 152. According to an exemplaryembodiment, each aperture 153 is configured to receive a fastener 142.The upper and lower members 154, 156 include an aperture 158 that isconfigured to allow the exposed portion of the bus bar 152 to beconductively coupled to a terminal 136, 138 of a cell 130.

Referring to FIG. 16, the washer assembly includes a member shown as aprinted circuit board 162 and a plurality of conductive members orwashers 164 coupled to the printed circuit board 162. According to anexemplary embodiment, the washers 164 are interconnection washers formedfrom a conductive material such as a metal (e.g., copper, copper alloy,aluminum, aluminum alloy, etc.). Each washer 164 is coupled (e.g.,soldered, welded, etc.) to a dedicated conductive line or wire 163 onthe printed circuit board 162. Note that only a single conductive lineis shown; although it should be noted that according to an exemplaryembodiment, there is a separate conductive line for each washer.

According to an exemplary embodiment, a plurality of connectors 165 areelectrically connected to the conductive lines 163 and are configured toelectrically connect the washers 164 to a control system (e.g., abattery management system). According to another exemplary embodiment,the connectors 165 are crimped onto the printed circuit board 162.According to an exemplary embodiment, the printed circuit board 162 is aflexible printed circuit board constructed of a flexible material suchas Mylar® or another suitable material. According to an exemplaryembodiment, the conductive line 163 (e.g., a lead line) connects each ofthe washers 164 to the connectors 165 to aid in measuring the voltage ofthe electrochemical cell 130.

As shown in FIGS. 17-22, according to an exemplary embodiment, eachwasher 164 includes an aperture 166 that is configured to be alignedabove an aperture 153 of an underlying bus bar 152 to receive a fastener142 for coupling the washer 164 to a terminal 136, 138 of an associatedcell 130. According to an exemplary embodiment, the fastener 142includes threads 144 that are configured for threaded engagement withinternal threads (not shown) of the terminals 136, 138. According toanother exemplary embodiment, a washer 146 may be used with fastener 142to aid in compressing the washer 164 (and the bus bar 152) to the top ofthe terminals 136, 138. According to an exemplary embodiment, the washer146 has an external diameter that is smaller than the exposed portion ofthe washer 164 such that a substantial portion of the washer 146 is incontact with the washer 164 (see, e.g., FIGS. 18 and 21).

As shown in FIG. 19, according to an exemplary embodiment, the washer164 may have a plating 170. According to an exemplary embodiment, theplating is a tin plating and is used to couple the washer 164 to theprinted circuit board 162. According to an exemplary embodiment, asoldering area 168 may be provided on the printed circuit board 162.According to an exemplary embodiment, the soldering area 168 is a copperor copper alloy pad. According to an exemplary embodiment, the washerassembly 160 may include a cover or member shown as coverlay 174configured to substantially cover (and insulate) the conductive lines onthe printed circuit board 162 that connect the washers 164 to theconnectors 165.

Referring now to FIGS. 23-24, a washer 164 is shown according to anotherexemplary embodiment. As shown in FIGS. 23-24, the washer 164 includes agenerally circular inner circumference which defines an aperture 166 anda generally circular outer circumference. According to one exemplaryembodiment, the outer circumference of the washer 164 includes a flatedge or portion 176. According to an exemplary embodiment, the washer164 includes two flat portions 176 opposed from one another on oppositesides of the washer 164. According to an exemplary embodiment, the flatportion 176 is provided to ensure that a clearance space is providedbetween adjacent washers 164.

According to an exemplary embodiment, the washer 164 is welded orsoldered all along the outer circumference of the washer 164 to theprinted circuit board 162. According to another exemplary embodiment, asshown in FIGS. 23-24, the washer 164 is soldered only along the circularportions of the outer circumference at the soldering areas 168.According to other exemplary embodiments, the washers may be soldered tothe printed circuit board 162 at any suitable locations.

According to one exemplary embodiment, the washer 164 has an externaldiameter of about 15 mm, but may vary more or less according to otherexemplary embodiments. According to another exemplary embodiment, washer164 has an internal diameter of about 6.5 mm, but may vary more or lessaccording to other exemplary embodiments. According to another exemplaryembodiment, the washer 164 has a thickness of about 0.2 mm, but may varymore or less according to other exemplary embodiments. According to oneexemplary embodiment, the washer 164 is a flexible washer or asemi-flexible washer. According to another exemplary embodiment, thewasher 164 may be a rigid or semi-rigid washer. According to anexemplary embodiment, the washer 164 is a generally flat, thin washer.

According to an exemplary embodiment, the printed circuit board 162includes a plurality of apertures 178. The apertures 178 are configuredto be aligned with the terminals 136, 138 of the cells 130 of thebattery module 120. According to an exemplary embodiment, a plurality ofwashers 164 are coupled to the circuit board 162 such that an innerdiameter 166 of the washers 164 is generally aligned with a central axisof the apertures 178 of the circuit board 162. The washers 164 are alsogenerally aligned with the apertures 153 of the bus bars 152 and withthe terminals 136, 138. According to an exemplary embodiment, the washerassembly 160 is configured to be substantially simultaneously coupled tothe terminals 136, 138 of the electrochemical cells 130 in order toconductively couple the washers 164 (and the bus bars 152) to theterminals 136, 138.

As utilized herein, the terms “approximately,” “about,” “substantially,”and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the exemplary embodiment asrecited in the appended claims.

It should be noted that the term “exemplary” as used herein to describevarious embodiments is intended to indicate that such embodiments arepossible examples, representations, and/or illustrations of possibleembodiments (and such term is not intended to connote that suchembodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two members directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two members or thetwo members and any additional intermediate members being integrallyformed as a single unitary body with one another or with the two membersor the two members and any additional intermediate members beingattached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,”“above,” “below,” etc.) are merely used to describe the orientation ofvarious elements in the FIGURES. It should be noted that the orientationof various elements may differ according to other exemplary embodiments,and that such variations are intended to be encompassed by the presentdisclosure.

It is important to note that the construction and arrangement of theinterconnection washer assembly as shown in the various exemplaryembodiments is illustrative only. Although only a few embodiments havebeen described in detail in this disclosure, those skilled in the artwho review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter described herein. Forexample, elements shown as integrally formed may be constructed ofmultiple parts or elements, the position of elements may be reversed orotherwise varied, and the nature or number of discrete elements orpositions may be altered or varied. The order or sequence of any processor method steps may be varied or re-sequenced according to alternativeembodiments. Other substitutions, modifications, changes and omissionsmay also be made in the design, operating conditions and arrangement ofthe various exemplary embodiments without departing from the scope ofthe present exemplary embodiment.

What is claimed is:
 1. A battery module, comprising: a plurality ofelectrochemical cells, each electrochemical cell comprising a terminal;a circuit board; and a plurality of interconnectors, wherein each of theplurality of interconnectors is coupled to the circuit board and to aterminal of one of the plurality of electrochemical cells, and whereineach of the interconnectors is a resilient spring-type interconnector.2. The battery module of claim 1, wherein each of the plurality ofinterconnectors comprises a pair of rings coupled together by anelastically-compliant member that is configured to flex in response to aforce.
 3. The battery module of claim 2, wherein theelastically-compliant member is configured to allow the pair of rings toflex relative to each other in response to a force.
 4. The batterymodule of claim 2, wherein a first of the rings is coupled to thecircuit board and a second of the rings is coupled to a terminal of oneof the plurality of electrochemical cells.
 5. The battery module ofclaim 2, wherein the elastically-compliant member is integrally formedwith the pair of rings.
 6. The battery module of claim 2, wherein afirst of the rings has a diameter smaller than a diameter of a second ofthe rings, and wherein the elastically-compliant member is helicallycurved with a diameter increasing from a connection point with the firstof the rings to a connection point with the second of the rings.
 7. Thebattery module of claim 2, wherein the elastically-compliant memberextends from an inner edge of a first of the rings to an outer edge of asecond of the rings.
 8. The battery module of claim 1, wherein each ofthe interconnectors is configured to act as a conductor for measuring avoltage of the associated electrochemical cell.
 9. The battery module ofclaim 1, wherein the circuit board is flexible.
 10. The battery moduleof claim 1, wherein at least one of the interconnectors is coupled to aconductor path on the circuit board.
 11. The battery module of claim 1,further comprising: a temperature sensor electrically coupled to theterminal of one of the plurality of electrochemical cells, thetemperature sensor configured to detect the temperature of the terminal.12. The battery module of claim 11, wherein the temperature sensor ismounted on the circuit board, and wherein one of the plurality ofinterconnectors electrically couples the temperature sensor to theterminal.
 13. The battery module of claim 1, further comprising: aconductive bar connecting the terminal of a first of the electrochemicalcells to the terminal of a second of the electrochemical cells, theconductive bar including a first copper part connected to the terminalof the first electrochemical cell, a second copper part connected to theterminal of the second electrochemical cell, and a shunt between thefirst copper part and the second copper part; and a voltage sensorconfigured to measure a voltage drop across the shunt.
 14. A batterymodule, comprising: a plurality of electrochemical cells, eachelectrochemical cell comprising a terminal; a circuit board; and aplurality of interconnectors, wherein each of the plurality ofinterconnectors is coupled to the circuit board and to a terminal of oneof the plurality of electrochemical cells, and wherein each of theinterconnectors is a resilient spring-type interconnector; wherein thecircuit board is configured to allow the plurality of interconnectors tobe substantially simultaneously conductively coupled to the terminals ofthe plurality of electrochemical cells.
 15. The battery module of claim14, wherein each of the plurality of interconnectors comprises a pair ofrings coupled together by an elastically-compliant member that isconfigured to flex in response to a force.
 16. The battery module ofclaim 15, wherein the elastically-compliant member is configured toallow the pair of rings to flex relative to each other in response to aforce.
 17. The battery module of claim 16, wherein a first of the ringsis coupled to the circuit board and a second of the rings is coupled toa terminal of one of the plurality of electrochemical cells.
 18. Abattery module comprising: a plurality of electrochemical cells, each ofthe electrochemical cells comprising a terminal projecting from an endthereof; and a member having a plurality of interconnectors coupledthereto, wherein each of the plurality of interconnectors is coupled toa terminal of one of the plurality of electrochemical cells to aid inmeasuring the voltage of the electrochemical cell.
 19. The batterymodule of claim 18, wherein each of the plurality of interconnectorscomprises a pair of rings coupled together by an elastically compliantmember that is configured to flex in response to a force.
 20. Thebattery module of claim 19, wherein a first of the rings is coupled tothe circuit board and a second of the rings is coupled to a terminal ofone of the plurality of electrochemical cells.